Apparatus for use in the construction of walls



Feb. 22, 1955 E. O'SULLIVAN 2,702,421

APPARATUS FOR USE IN THE CONSTRUCTION OF WALLS Filed Feb. 17, 1951 4 Sheets$heet 1 In venior Euaewe 0 '50; a 1/4 A itorne y Feb. 22, 1955 E, OSULLIVAN 2,702,421

APPARATUS FOR USE IN THE CONSTRUCTION OF WALLS Filed Feb. 17, 1951 4 Sheets-Sheet 2 Inventor fads/v6 d SUZLIVAA/ Attorney 1%. 22, 1955 E. OSULLIVAN 2,702,421

APPARATUS FOR USE IN THE CONSTRUCTION OF WALLS Filed Feb. 17, 1951 4 Sheets-Sheet 3 F/G 3. F/G. 4

InUen IO fuse/v5 d l' au Attorney Feb. 22, 1955 E. O'SULLIVAN 2,702,421

APPARATUS FOR USE IN THE CONSTRUCTION OF WALLS Filed Feb. 17, 1951 4 Sheets-Sheet 4 In ven'tor E0450? 0 (fuu/ w? y )2. rfiwz,

Attorne United States Patent APPARATUS FOR USE IN THE CONSTRUCTION OF WALLS Eugene OSullivan, Chislehurst, England Application February 17, 1951, Serial No. 211,467

Claims priority, application Great Britain February 24, 1950 9 Claims. (Cl. 25-131) This invention relates to apparatus for use in the contsltlruction of walls having window openings formed in These window openings require to be provided with sills and it is one of the principal objects of the present invention to provide apparatus by means of which a sill can be constructed in situ out of concrete or like material which can be cast in a mould and which will then set to allow the mould to be removed. All such materials are comprised within the term concrete which will be used for the sake of convenience in the following specification and claims.

A further object of the invention is the provision of apparatus for constructing a concrete sill which includes a pair of mould plates and means for removably supporting said plates in the correct positions relatively to the wall and to the window frame or surround for forming the inner and outer faces of the sill.

Another object of the invention is the provision of apparatus for use in constructing a sill out of concrete which includes means for supporting a window frame or surround above a section of wall below the window opening in such a position that the sill can be constructed so as to be supported by the wall and extending from one side of the wall to the other side thereof beneath the frame or surround.

A further object of the invention is the provision of such apparatus for supporting the window frame or surround which includes a weather bar adapted to form a seal with the frame or surround so as to prevent water from seeping under the latter.

The invention is also concerned with the formation of the sides of window openings in those cases in which the walls are formed in situ out of concrete or like materials which are cast or moulded in suitable moulds or shuttering.

When constructing walls in this manner difficulties are encountered in fitting the window frames or surrounds in the openings which have been left in the walls for this purpose, or, alternatively, in forming the end faces or reveals of the walls on opposite sides of the frames or surrounds if the latter have been erected in position before the portions of the wall on each side of them are constructed, as is usual in brick and similar forms of construction.

It is accordingly a further object of the invention to provide apparatus which is adapted to be used for forming the reveals at the sides of a window openind and which will enable a good bond or joint to be obtained between the concrete of the wall and the frame or surround.

Another object of the invention is the provision of apparatus which is adapted to be used in connection with the formation of these reveals and which is also capable of being used to assist in the construction of a lintel over the window opening.

Generally speaking, a window sill is required to project beyond the outer surface of the wall in order to carry water clear of the wall surface, while improving the appearance of the opening. Furthermore, it is generally preferred for the sill to project inside the wall.

Yet another object of the invention, therefore, is the provision of apparatus by means of which a sill can be constructed which projects on one or both sides of the wall, While a still further object of the invention is the provision of such apparatus which can be used for constructing a sill the length of which is greater than the width of the window opening.

For the better understanding of the invention in its various aspects the same will now be more fully'described, by way of example, with reference to the accompanying drawings.

In the drawings:

Figure 1 is an isometric view showing part of the apparatus of the invention which has been assembled in position to form a window opening in a concrete cavity wall;

Figure 2 is a view similar to Figure 1 but showing a later stage in the construction and illustrating more particularly the construction of the sill;

Figure 3 is a vertical section taken through the lower part of the window opening showing the apparatus used for forming the sill;

Figure 4 is an elevational view, taken from the inner side of the wall, showing the apparatus of Figure 3;

Figure 5 is a detail view illustrating the method of attaching the sill mould plates to one of the connecting members used for supporting them;

Figure 6 is an elevational view of one of the reveal plates;

Figure 7 is a section taken on the line V11VH of Figure 6;

Figure 8 is a cutaway elevational view showing one of the struts used for positioning the reveal plates.

Referring more particularly to Figure 1, the references 1 and 2 indicate parts of a concrete cavity wall which has been constructed up to the required level of the bottom of the sill, using any suitable moulds or shuttering such as, for example, the moulds which are described in the specification of application No. 143,306.

When this level has been reached the top of the cavity 3 in the wall is closed by means of slates, tiles or other suitable cavity sealing members 4, which are laid in position across the cavity resting loosely on the wall.

In order that the sill which is to be constructed may extend across the width of the wall underneath the window surround, which is indicated at 5, the latter must be supported at an appropriate distance above the sealing members 4. To do this a support member 6 (see also Figures 2, 3 and 4) is provided. This consists of a bar made of steel or other suitable material which is provided with a number of pairs of legs 7 which are adapted to rest on the sealing members 4 in the manner shown in the drawings. These legs 7 may consist of lengths of strip steel which are bent at their mid points, where they are attached to the bar 6, preferably by welding.

When the support 6 has been fitted the surround 5 is rested on it in the position which it is to occupy in the finished wall. The surround is held upright by means of suitable struts (not shown) which are fitted between it and the ground or some other convenient fixed object.

Generally speaking, the surround 5 will be formed with a groove 8 which extends round it and this groove is fitted over the support bar 6 as shown in the drawings.

It should be noted that it is intended that the support bar 6 with its legs 7 should remain in the sill after the latter has been constructed and the bar 6 will then act as a weather bar to prevent water creeping between the sill and the surround.

In order to ensure that the surround 5 makes a good joint with the support bar 6, and also with the concrete sill, it is preferred to coat the underneath surface of the surround with a layer of mastic 59 (Figure 3) which fills the groove 8 on each side of the bar 6.

Once the surround 5 has been fitted in the manner described the reveal plates 9 are assembled in the appropriate positions. Each of these plates, of which four are used, consists of a sheet of steel the edges of which are strengthened by means of lengths of angle steel 10, 11, 12 and 13 (see Figures 6 and 7), which are secured to the steel sheet, preferably by welding. Alternatively the plates 9 could be provided with strengthening flanges simply by bending back the edges of the sheets at right angles.

Each plate 9 is provided with two clips 14 which are used for supporting the plates in the correct positions. Each of these clips is formed of a piece of sheet steel which is bent into the form of a U, one side of which is attached to the inner face of the plate 9, as by welding.

The reveal plates 9 are held in position at the required distance apart against the inner and outer faces of the side members of the surround by means of two telescopic struts 15, one of which is shown in position in Figure 1 and is illustrated in greater detail in Figure 8.

Each of the struts 15 consists of tubular inner and outer members 16 and 17 respectively, which are longitudinally adjustable one within the other. Each of these members is provided at its end with a stirrup-shaped bracket 18 which is formed of a length of steel strip. This strip is bent into the form of a U and its ends are bent outwardly at right angles to form feet 19, as is best shown in Figure 8. The brackets 18 are connected with the members 16 and 17 by means of tubular sockets 20 which are Welded to the brackets and which receive the ends of the said members 16 and 17. These members may be permanently secured in the sockets 20 by welding or otherwise, or it would be possible for them to be removably fitted into the sockets.

The brackets 18 are provided with inner shaping members, which in the construction shown consist of angle pieces 21 which are welded in position in one corner of the U of each of the brackets. These shaping members are intended to engage against parts of the surround 5 (or against a casement or frame fitted in it) when the bracket is in the correct position, and the shape of the members will therefore de end on the particular type of surround or frame with which the apparatus is intended to be used.

The inner and outer telescopic members 16 and 17 are formed with series of spaced holes 22 and 23 respectively, throu h which a pin 24 can be fitted. In this way the len th of the strut can be adjusted to suit the width of the window.

To assemble this part of the apparatus the feet 19 of the brackets 18 are enga ed in the cli s 14 in the manner shown in Figure 1, it being noted that the webs of the angle members are cut away opposite the clips, as shown at 25, in order to facilitate the fitting and removal of the brackets 18.

With the construction shown it is assumed that the clips .14 are resilient and that they grip the brackets 18 sufficiently firmly to su port the latter, together with the struts 15. If desired. however. means could be provided for preventing the brackets from dropping out of enga ement with the cli s, or the clips 14 could be fitted to the reveal plates so that the open ends of the clips face upwardly.

Once the reveal plates have been fitted in position the construction of the walls is continued, as is indicated at 26 in Figure 1, using the appropriate moulds or shuttering. It will be noted that the concrete of the wall comes in contact with the surro nd 5, thus ensuring that the latter is firmly held in position. made of wood its outer surface may be covered with a layer of mastic in order to obtain a good bonding with the concrete and to ensure that a watertight joint is obtained.

Once the walls have been constructed up to the to of the surround 5, as shown in Figure 2, the struts and reveal plates 9 are removed, after which the construction of a lintel across the top of the window opening may be effected. This lintel. which is not shown in the drawin s, may be formed in situ out of concrete by the method and using the apparatus described in the specification of application No. 4,335. Such apparatus includes a lintel box or mould and the struts 15 of the present invention are so designed that they can be used for supporting the bottom of this lintel box. connection it will be noted that the brackets 18 are so shaped that, when a strut is fitted vertically in the window opening, the lower bracket 18 with its shaping member 21 will bear on the bottom of the surround 5, while the upper bracket 18 will engage the top of the surround with the feet 19 of the bracket level with the upper surface of the surround in positions to support the bottom of the lintel box.

When the lintel has been constructed the lintel box, together with the struts 15 are removed, after which the construction of the walls can be continued above the window opening.

The sill can be constructed at any convenient time after the lintel or, alternatively, the construction of the lintel might be effected after the sill has been formed.

If the surround is In this In this latter case the feet 19 of the lower brackets 18 would rest on the upper surface of the sill during the building of the lintel. The shaping members 21 could still engage the surround 5 since the depth of the brackets 18 beyond the members 21 is made equal to the thickness of the surround.

The apparatus for constructing the sill comprises inner and outer sill mould plates 27 and 28 respectively, a pair of connecting members 29 and a pair of clamping members 30, together with a pair of pressure distribution members 31 which are fitted between the members 29 and 30.

The inner mould plate 27 consists of a piece of angle steel the length of which is equal to the required length of the sill. This will generally be rather greater than the width of the window opening so that the sill will extend beyond the sides of the latter, as is shown in Figure 2. The depth of the vertical flange 32 of the mould plate 27 is made equal to the desired thickness of the sill on the inner side thereof, while the width of the lower horizontal-flange or lip 33 is made equal to the amount by which the sill is desired to project or overhang on the inner side of the wall, this distance being measured from the face of the wall proper before the application of any plaster or other lining.

Similarly, the outer mould plate 28, which is of the same length as the plate 27, has a depth for its vertical flange 34 which is equal to the desired thickness of the sill on the outer edge thereof, while the width of the lower lip or flange 35 corresponds to the intended amount of the overhang of the sill on the outside of the wall.

In order to form a drip channel beneath the overhanging portion of the sill, so as to cause the water to drip clear of the face of the wall, a rib 36 is provided near the inner edge of the lip 35 of the outer mould plate 28. This rib is shown as being formed of a length of steel bent to the form of a quarter circle and welded to the lip 35, but a solid rib of quadrant or other suitable section could be provided if desired.

Each of the connecting members 29, which is used for supporting the mould plates 27 and 28, consists of a cross part 37 which is adapted to extend through the window opening so as to rest on the lower part of the window frame or surround, a pair of side arms 38, which are connected to the ends of the cross part 37 at right angles to the latter and which in use extend substantially hOllzontally and parallel to each other beyond the sides of the window opening, and a pair of downwardly extending legs 39 which are secured to the ends of the arms 38. The cross part 37 is shown as being made of flat sheet steel while the arms 38 and legs 39 are made of angle material. The various parts are connected together by welding.

At the lower ends of the legs 39 two feet 40, which are also made of angle material, are provided, while plates 41 are secured, as by welding, to the outer sides of the legs 39 and feet 40. These plates 41 carry short ribs 42 which are secured to them along their upper edges.

The parts 39, 40, 41 and 42 are so dimensioned and arranged that they form sockets into which the ends of the mould plates 27 and 28 can be fitted, as is shown in the drawings.

The connecting members 29 are also provided with 7 pairs of end plates 43 which are secured, as by welding,

to the inner faces of the legs 39. These plates are intended to form the end faces of the projecting ends of the sill, as is shown in Figure 2.

Since the part of the sill on the outer side of the window surround should slope outwardly in order to ensure that the water will run off it one of the legs 39 of each of the members 29 may be made longer than the other, as is shown in Figure 3. The top of the sill inside the window may be level.

The clamping members 30 are intended to be fitted between the sides of the window frame or surround and the connecting members 29, with the interposition of the pressure distribution members 31, so as to draw the members 29 towards each other and thus to ensure that they hold the mould plates 27 and 28 firmly in the correct position for forming the sill.

The clamping members which are shown in the drawings are designed for use with a standard type of steel frame or casement, a part of which is indicated at 44 in the drawings. This casement is fitted in the surround 5 in the usual manner.

Each of the members 30 consist of a pair of wedge plates 45 which are secured, as by welding, on opposite sides of a distance piece 46 the width of which is such that the edges of the plates 45 engage one on each side of the easement 44 with the spacing member 46 pressed against the edge of the latter.

The wedge plates 45 are tapered so as to be wider at the top than at the bottom, so that when they are forced downwardly between the easement 44 and the members 31 they force the latter, and with them the connecting members 29, inwardly towards the centre of the window. Thus the connecting members 29 are securely clamped in position with their socket portions firmly engaging the ends of the mould plates 27 and 28.

The pressure distribution members 31 are intended to distribute the pressure of the members 30 on the cross parts 37 of the connecting members 29. They may be constructed in any suitable manner. In the construction shown in the drawings (see Figures 3 and 4) each pressure distribution member is formed of a flat plate 47 and of two angle members 48 and 49. These parts are welded together in the relative positions shown in the drawings and are fitted with the angle member 49 engaging the cross part 38 of the connecting member 29 and with the plate 47 engaged by the wedge plates 47 of the member 30.

As an alternative to using separate pressure distribution members 31 such members could be provided as parts of the members 29, or the clamping members 30 could be designed to fit directly between the easement 44 and the parts 38 of the members 29.

Should it be desired to construct the sill before fitting the casement 44 in the surround the members 30 could be modified so as to engage between the surround 5 itself and the members 30 or 29 as the case may be.

When the mould plates 27 and 28 with the associated parts have been fitted in position in the manner described the sill 50 is formed by running concrete into the spaces between the mould plates 27 and 28. The concrete is worked in so as to form a continuous sill which extends beneath the surround 5 and which engages the mastic coating 59 on the underside of the surround. The support bar 6 and its legs 7 are embedded in the concrete, as is shown in Figures 2 and 3, and form part of the sill structure, which they serve to reinforce.

The upper surface of the concrete may be worked to provide a smooth finish, the surface of the sill n the inner side of the window being made substantially level ready to receive a quarry tile or wooden sill if desired, while the surface on the outer side of the window is given a downward slope to ensure that the water will run olf it.

When the concrete has hardened sufliciently the clamping members 30 with the pressure distribution members 31 are removed, which allows the connecting members 29 to be disengaged from the ends of the mould plates 27 and 28. This allows these plates to be removed leaving the sill in position.

Various modifications are possible in the apparatus which has been described.

For example the brackets 18, instead of being detachable from the reveal plates 9, could be more or less permanently attached to the latter, as by bolting, welding or in some other suitable manner. The distance between the edges of the plates would be made to correspond to the thickness of the surrounds with which the plates are intended to be used or, if desired, means could be provided for enabling the distance between the reveal plates to be adjusted as required, for example by connecting them to the brackets 18 by means of bolts passing through slots formed in the feet 19. In any such arrangement the struts would be made detachable from the brackets 18.

According to another modification the struts 15 could be dispensed with, in which case other means would be provided for holding the reveal plates 9 in position. For example, the brackets 18 could be provided with releasable cam-operated clamping bolts or other members for attaching them to the surround 5.

The reveal plates could be made the full height of the opening, as shown, or shorter plates could be used which are progressively raised as the construction of the wall proceeds.

In most cases the apparatus will be so constructed that the front or outer faces of the reveal plates lie in the same plane but it would be possible, if desired, to atrange for the plane of one plate to be offset with respect to the plane of the other, or the plates could be arranged at an angle to each other.

The invention is also applicable to the construction of window openings in which no wooden or equivalent surround is used but in which the frame of the window is mounted directly in the concrete of the wall. In such cases the reveal plates 9 would be fitted against the window frame itself, the shape of the brackets 18 being suitably modified in order to hold the reveal plates in the required positions. If desired the reveal plates could be so shaped that they in eifect produce a concrete surround to the frame.

I claim:

1. Apparatus for use in the construction of a wall having a window opening provided with a concrete sill having faces exposed on the inner and outer sides of the wall, said apparatus comprising a pair of sill mould plates, a pair of connecting members adapted to be fitted in spaced relation through said opening and means detachably connecting said connecting members with said plates so as to support the latter in generally parallel, spaced-apart relation in order to form the said faces of said sill when the latter is cast between said plates on top of the part of said wall beneath said opening, the space between said mould plates and between said connecting members being open at the top to permit the introduction of concrete to form the sill, at least one of said sill mould plates being provided with an inwardly extending lower lip adapted to form the underneath face of the overhanging portion of said sill, said lower lip containing an upstanding rib which is spaced from the inner face of said mould plate in a position to form a drip groove on the underneath face of the overhanging portion of said sill.

2. Apparatus as claimed in claim 1, wherein the means connecting said connecting members with said mould plates include socket formations provided on said connlecting members and adapted to receive the ends of said p ates.

3. Apparatus as claimed in claim 1 wherein said sill mould plates are of greater length than the width of said openings, socket formations on the said connecting members spaced from the center portions thereof so as to receive the ends of said plates.

4. Apparatus for use in the construction of a wall having a window opening provided with a concrete sill having faces exposed on the inner and outer sides of the Wall, said apparatus comprising a pair of sill mould plates, 3 pair of connecting members adapted to be fitted in spaced relation through said opening and means detachably connecting said connecting members with said plates so as to support the latter in generally parallel, spaced-apart relation in order to form the said faces of said sill when the latter is cast between said plates on top of the part of said wall beneath said opening, the space between said mould plates and between said connecting members being open at the top to permit the introduction of concrete to form the sill, each of said connecting members comprising a cross part adapted to extend through said opening, a pair of side arms extending from the ends of said cross part, a pair of legs depending from said side arms, and socket formations carried by said legs adapted to receive the ends of said plates.

5. Apparatus for use in the construction of a wall having a window opening provided with a sill, which sill includes a part which overhangs the wall on at least one side thereof, said apparatus comprising a pair of sill mould plates, a pair of connecting members adapted to be fitted in spaced-apart relation through the window opening, means connecting said connecting members with said plates so as to support the latter in spaced-apart relation in order to form the inner and outer faces of the sill, at least one of said mould plates being provided with an inwardly-extending lower lip for forming the underneath face of the overhanging part of the sill, and means for closing the spaces between the ends of said plate and the wall for forming the end faces of the said overhanging part.

6. Apparatus as claimed in claim 5, wherein the said lower lip is provided with an upstanding rib which is spaced from the inner face of said mould plate in a position to form a drip groove on the underneath face of the overhanging portion of said sill.

7. Apparatus as claimed in claim 5, wherein the means connecting said connecting members with said mould plates include socket formations provided on said connecting members and adapted to receive the ends of said p ates.

8. Apparatus as claimed in claim 5, wherein each of said connecting members comprises a cross part adapted to extend through said opening, a pair of side arms extending from the ends of said cross part and a pair of legs depending from said side arms, said socket formations being carried by said legs.'

9. Apparatus as claimed in claim 5, wherein the means closing the spaces between the ends of said sill mould plates and the wall comprise end plates forming parts of said connecting members.

References Cited in the file of this patent UNITED STATES PATENTS 

